The Spool Welding Robot welding a pipe at a fabrication shop.
Case Study

WPF

Overcoming Workforce and Efficiency Challenges at WPF (Formerly Wilson’s Pipe Fabrication)

WPF, a company based in Western Australia with operations nationally, is a leader in multi-discipline engineering services for the Australian energy sector. Renowned for handling diverse materials, from carbon steel to exotic alloys like duplex and copper nickel, WPF serves some of the most demanding energy producers in the world. Their commitment to quality, with stringent internal acceptance criteria, often exceeding code requirements, sets them apart. Fabricating across multiple workshops in Western Australia and the Northern Territory, WPF ensures material segregation and process integrity while delivering exceptional results.

 

Operational Challenges

 

The tight labor market in Australia presented a significant challenge for WPF. Skilled coded welders capable of adapting to various conditions and fit-ups were scarce, making it difficult to maintain production efficiency and quality. Furthermore, the high cost and disruption caused by weld repairs, estimated to be similar to North America’s average of $1,000 per weld, added pressure to maintain repair rates below 1%.

WPF’s reliance on traditional welding methods also introduced inefficiencies. While their manual processes were effective, scaling production without compromising quality or safety proved challenging. The need for a solution that could increase productivity while preserving their reputation for exceptional quality became a priority.

SWR at WPF

The Solution: Novarc’s Spool Welding Robot (SWR™)

After evaluating semi-automated options, WPF turned to Novarc’s Spool Welding Robot (SWR™). Unlike other solutions, the SWR stood out as a purpose-built robotic system for pipe welding. Its ability to automate root, fill, and cap passes, combined with advanced seam tracking and rotator communication, offered a comprehensive solution tailored to WPF’s needs.

The decision to invest in the SWR™ was driven by its compact design, high-quality welds, and ability to alleviate reliance on highly skilled welders. WPF’s setup included four positioners, enabling a production-line approach where multiple team members could work simultaneously. This configuration optimized material handling and welding processes, enhancing efficiency.

The learning curve for WPF’s operators was well-supported by Novarc’s team. The SWR™ also proved instrumental in extending the careers of older welders by reducing the physical strain and enabling them to continue contributing to high-quality work.

Productivity Gains

Geometry dependent, WPF reported a 40-60% reduction in weld time across initial projects, significantly accelerating project timelines and enabling the company to confidently take on larger, more complex jobs.

Weld quality

Quality Assurance

With the SWR™’s automated passes and advanced seam tracking, WPF achieved repair rates consistently below 1%. This precision reduced costly rework and optimized quality assurance efforts. During initial stages, when completing qualifications, WPF exceeded industry standards by identifying, then testing welds at their weakest points, fine tuning the employed methodology and parameters, and enabling consistent mechanical properties to be achieved. This exceeded ASME requirements and has set a new benchmark for quality in the industry.

Strategic Benefits

The introduction of the SWR™ has strengthened WPF’s position as a market leader in welding automation in Australia. The robot’s performance has allowed the company to bid more competitively while maintaining margins.

A Partnership Built on Trust

Throughout the process, Novarc’s team provided exceptional support, from commissioning to troubleshooting, ensuring WPF maximized the SWR’s potential. Mitch Wilson, General Manager at WPF, shared, “The support from Novarc has been absolutely fantastic. The relationship we have with their team is solid from the top down.”

The Future of Pipe Fabrication

WPF’s investment in Novarc’s Spool Welding Robot highlights how adopting advanced technology can overcome labor shortages, improve productivity, and uphold the highest quality standards. By combining innovative robotics with thoughtful operational strategies, WPF is setting new standards for efficiency and innovation in pipe fabrication.

As Mitch Wilson remarked, “The SWR™ has positioned us to be market leaders here in Western Australia, and even Australia. We’re excited to get the most out of our unit in 2025.”

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